Modular box assembly

ABSTRACT

A modular box assembly includes a box with side panels defining a box cavity, a first thermal liner positioned within the box cavity, the first thermal liner including a first insulation batt disposed between sheets, the first thermal liner defining three first liner panels, at least one box side panel being covered by a first liner panel, and a second thermal liner positioned within the box cavity, the second thermal liner including a second insulation batt disposed between sheets, the second thermal liner defining three second liner panels. At least one other of the side box panels is covered by a second liner panel. The bottom box panel is covered by either a first liner panel not covering any side box panel or a second liner panel not covering any side box panel. Each insulation batt can be formed from a mixture of thermoplastic binder fibers and reinforcement fibers.

REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/689,407, filed Nov. 20, 2019, which is a continuation of U.S.application Ser. No. 15/663,905, filed Jul. 31, 2017, now U.S. Pat. No.10,551,110, and both of those applications are hereby specificallyincorporated by reference herein in their entireties.

TECHNICAL FIELD

This disclosure relates to packaging. More specifically, this disclosurerelates to a modular box assembly.

BACKGROUND

Packaging and shipping temperature sensitive contents can posechallenges. The contents can spoil, destabilize, freeze, melt, orevaporate during storage or shipping if the temperature of the contentsis not maintained or the packaging is not protected from hot or coldenvironmental conditions. In applications such as hot food delivery,customers can be dissatisfied if the contents have cooled to ambienttemperature upon delivery. Contents such as food, pharmaceuticals,electronics, or other temperature sensitive items can be damaged ifexposed to temperature extremes. Many insulated packages are bulky anddifficult to store prior to use. Additionally, many insulated packagesare specialized to ship or carry hot goods, chilled goods, or frozengoods, and shippers must maintain large stocks of specialized packagingfor each application. Additionally, many insulated packages cannot berecycled and are often disposed of in landfills.

SUMMARY

It is to be understood that this summary is not an extensive overview ofthe disclosure. This summary is exemplary and not restrictive, and it isintended to neither identify key or critical elements of the disclosurenor delineate the scope thereof. The sole purpose of this summary is toexplain and exemplify certain concepts of the disclosure as anintroduction to the following complete and extensive detaileddescription.

Disclosed is a modular box assembly comprising a box, the box comprisinga bottom box panel and four side box panels, the four side box panelsand the bottom box panel defining a box cavity; a first thermal linerpositioned within the box cavity, the first thermal liner comprising afirst sheet, a second sheet, and a first insulation batt disposedbetween the first sheet of the first thermal liner and the second sheetof the first thermal liner, the first thermal liner defining three firstliner panels, wherein at least one side box panel is covered by a firstliner panel; and a second thermal liner positioned within the boxcavity, the second thermal liner comprising a first sheet, a secondsheet, and a second insulation batt disposed between the first sheet ofthe second thermal liner and the second sheet of the second thermalliner, the second thermal liner defining three second liner panels,wherein at least one other of the side box panels is covered by a secondliner panel. The bottom box panel is covered by one of a first linerpanel not covering any side box panel and a second liner panel notcovering any side box panel. Each of the first insulation batt and thesecond insulation batt can be formed from a mixture of thermoplasticbinder fibers and reinforcement fibers.

Also disclosed is a method of manufacturing a modular box assembly,comprising the steps of constructing batt material by combiningthermoplastic binder fibers and reinforcement fibers to result in afibrous web, heating the fibrous web to a temperature exceeding a glasstransition temperature of the thermoplastic binder fibers, resulting inmelting of the thermoplastic binder fibers, and cooling the textilebatt, the cooling causing the binder fibers to solidify and to couplereinforcement fibers together; constructing a first thermal liner bypositioning a first insulation batt between a first sheet and a secondsheet to form a first laminated member and by folding portions of thefirst laminated member to define three first liner panels; constructinga second thermal liner by positioning a second insulation batt between afirst sheet and a second sheet to form a second laminated member and byfolding portions of the second laminated member to define three secondliner panels, wherein each of the first insulation batt and the secondinsulation batt is formed from the batt material; positioning the firstthermal liner in a box cavity defined by a box; and positioning thesecond thermal liner in the box cavity such that the first thermal linerand the second thermal liner together form an insulated cavity withinthe box cavity.

Various implementations described in the present disclosure may includeadditional systems, methods, features, and advantages, which may notnecessarily be expressly disclosed herein but will be apparent to one ofordinary skill in the art upon examination of the following detaileddescription and accompanying drawings. It is intended that all suchsystems, methods, features, and advantages be included within thepresent disclosure and protected by the accompanying claims. Thefeatures and advantages of such implementations may be realized andobtained by means of the systems, methods, features particularly pointedout in the appended claims. These and other features will become morefully apparent from the following description and appended claims, ormay be learned by the practice of such exemplary implementations as setforth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and components of the following figures are illustrated toemphasize the general principles of the present disclosure. The drawingsare not necessarily drawn to scale. Corresponding features andcomponents throughout the figures may be designated by matchingreference characters for the sake of consistency and clarity.

FIG. 1 is a perspective view of a modular box assembly comprising aninsulated box, a box top, and a carrying accessory in accordance withone aspect of the current disclosure.

FIG. 2 is a perspective view of the modular box assembly of FIG. 1 withthe insulated box of FIG. 1 in an open position.

FIG. 3 is a cross-section of the insulated box of FIG. 1 taken alongline 3-3 shown in FIG. 2 .

FIG. 4 is a cross-section of the modular box assembly of FIG. 1 takenalong line 4-4 shown in FIG. 2 .

FIG. 5 is a perspective view of a method for manufacturing an insulatedpanel in accordance with another aspect of the current disclosure.

FIG. 6A is a perspective view of another aspect of an insulated panel inaccordance with another aspect of the current disclosure prepared forinstallation on the insulated box of FIG. 1 .

FIG. 6B is a perspective view of the insulated panel of FIG. 6Apartially installed on the insulated box of FIG. 1 .

FIG. 6C is a perspective view of the insulated panel of FIG. 6Acompletely installed on the insulated box of FIG. 1 .

FIG. 7 is a top view of a box blank of the insulated box of FIG. 1without insulated panels.

FIG. 8 is a perspective view of the insulated box of FIG. 1 in acollapsed configuration.

FIG. 9 is a top view of the carrying accessory of the modular boxassembly of FIG. 1 .

FIG. 10 is a perspective view of the modular box assembly comprising theinsulated box of FIG. 1 and another aspect of a box top in accordancewith another aspect of the present disclosure.

FIG. 11 is a perspective view of the modular box assembly comprising theinsulated box of FIG. 1 and another aspect of a box top in accordancewith another aspect of the present disclosure.

FIG. 12 is a perspective view of the modular box assembly comprising theinsulated box of FIG. 1 and another aspect of a box top in accordancewith another aspect of the present disclosure.

FIG. 13 is a top view of a handle top in accordance with another aspectof the present disclosure.

FIG. 14 is a perspective view of another aspect of the modular boxassembly in accordance with another aspect of the present disclosurecomprising the box of the insulated box of FIG. 1 and the handle top ofFIG. 13 .

FIG. 15 is a perspective view of an inner box in accordance with oneaspect of the present disclosure.

FIG. 16 is a top view of an inner box blank of the inner box of FIG. 15.

FIG. 17 is a perspective view of another aspect of the insulated box inaccordance with another aspect of the present disclosure.

FIG. 18 is a perspective view of an outer sleeve of the modular boxassembly in accordance with another aspect of the present disclosure.

FIG. 19 is a perspective view of a support bracket of the modular boxassembly in accordance with another aspect of the present disclosure.

FIG. 20 is a downward cross-section of another aspect of the modular boxassembly comprising the inner box of FIG. 15 , the insulated box of FIG.17 , and the outer sleeve of FIG. 18 in accordance with another aspectof the present disclosure.

FIG. 21 is a side cross-section of the modular box assembly of FIG. 20 ,further comprising the handle top of FIG. 11 and a bottom insulatedpanel in accordance with another aspect of the present disclosure.

FIG. 22 is a side cross-section of another aspect of the modular boxassembly comprising the insulated box of FIG. 17 , the outer sleeve ofFIG. 18 , the support bracket of FIG. 19 , a divider panel, andtemperature maintaining packs in accordance with another aspect of thepresent disclosure.

FIG. 23 is an exploded perspective view of another aspect of theinsulated box in accordance with another aspect of the presentdisclosure.

DETAILED DESCRIPTION

The present disclosure can be understood more readily by reference tothe following detailed description, examples, drawings, and claims, andthe previous and following description. However, before the presentdevices, systems, and/or methods are disclosed and described, it is tobe understood that this disclosure is not limited to the specificdevices, systems, and/or methods disclosed unless otherwise specified,and, as such, can, of course, vary. It is also to be understood that theterminology used herein is for the purpose of describing particularaspects only and is not intended to be limiting.

The following description is provided as an enabling teaching of thepresent devices, systems, and/or methods in its best, currently knownaspect. To this end, those skilled in the relevant art will recognizeand appreciate that many changes can be made to the various aspects ofthe present devices, systems, and/or methods described herein, whilestill obtaining the beneficial results of the present disclosure. Itwill also be apparent that some of the desired benefits of the presentdisclosure can be obtained by selecting some of the features of thepresent disclosure without utilizing other features. Accordingly, thosewho work in the art will recognize that many modifications andadaptations to the present disclosure are possible and can even bedesirable in certain circumstances and are a part of the presentdisclosure. Thus, the following description is provided as illustrativeof the principles of the present disclosure and not in limitationthereof.

As used throughout, the singular forms “a,” “an” and “the” includeplural referents unless the context clearly dictates otherwise. Thus,for example, reference to “an element” can include two or more suchelements unless the context indicates otherwise.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

For purposes of the current disclosure, a material property or dimensionmeasuring about X or substantially X on a particular measurement scalemeasures within a range between X plus an industry-standard uppertolerance for the specified measurement and X minus an industry-standardlower tolerance for the specified measurement. Because tolerances canvary between different materials, processes and between differentmodels, the tolerance for a particular measurement of a particularcomponent can fall within a range of tolerances.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event or circumstance can or cannot occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not.

The word “or” as used herein means any one member of a particular listand also includes any combination of members of that list. Further, oneshould note that conditional language, such as, among others, “can,”“could,” “might,” or “may,” unless specifically stated otherwise, orotherwise understood within the context as used, is generally intendedto convey that certain aspects include, while other aspects do notinclude, certain features, elements and/or steps. Thus, such conditionallanguage is not generally intended to imply that features, elementsand/or steps are in any way required for one or more particular aspectsor that one or more particular aspects necessarily include logic fordeciding, with or without user input or prompting, whether thesefeatures, elements and/or steps are included or are to be performed inany particular aspect.

Disclosed are components that can be used to perform the disclosedmethods and systems. These and other components are disclosed herein,and it is understood that when combinations, subsets, interactions,groups, etc. of these components are disclosed that while specificreference of each various individual and collective combinations andpermutation of these may not be explicitly disclosed, each isspecifically contemplated and described herein, for all methods andsystems. This applies to all aspects of this application including, butnot limited to, steps in disclosed methods. Thus, if there are a varietyof additional steps that can be performed it is understood that each ofthese additional steps can be performed with any specific aspect orcombination of aspects of the disclosed methods.

Disclosed is a modular box assembly and associated methods, systems,devices, and various apparatus. The modular box assembly comprises abox, a box top, and a carrying accessory. It would be understood by oneof skill in the art that the disclosed modular box assembly is describedin but a few exemplary embodiments among many. No particular terminologyor description should be considered limiting on the disclosure or thescope of any claims issuing therefrom.

FIG. 1 is a perspective view of a modular box assembly 100 in a closedposition in accordance with one aspect of the present disclosure. Themodular box assembly 100 can comprise a box 101 and a variety ofaccessories configured to adapt the box 101 for different applications,such as shipping hot goods, chilled goods, frozen goods, or goods atambient temperature. FIGS. 1-23 depict these accessories as well asseveral different exemplary configurations for the box 101.

In the present aspect, the modular box assembly 100 can comprise the box101, a carrying accessory 170, and a box top 190. The box 101 can beconfigured as one aspect of an insulated box 110 comprising a pluralityof insulated panels 130 a-d (insulated panels 130 c,d shown in FIG. 3 ).The box 101 can comprise a rigid board material such as corrugatedcardboard; however in other aspects, the box 101 can comprise othersuitable rigid board materials, such as wood, plastic, metal, or anyother material. The insulated box 110 can be configured to transporthot, chilled, or frozen goods, and the insulated panels 130 a-d canmaintain a desired temperature within the insulated box 110. In otheraspects, the box 101 can be configured as an uninsulated box, such aswhen goods are transported at ambient temperature.

The box 101 can comprise a first pair of opposing side panels 112 a,band a second pair of opposing side panels 122 a,b. The side panels 112a,b,122 a,b can each be a rigid panel. The side panel 112 a can besubstantially parallel to the side panel 112 b, and the side panel 122 acan be substantially parallel to the side panel 122 b. Each side panel112 a,b can be substantially perpendicular to both side panels 122 a,b.The box 101 can define a rectangular or square cross-sectional shape;however, in other aspects, the box 101 can define a differentcross-sectional shape such as a circular, triangular, pentagonal, orhexagonal, shape or any other desired shape.

The box 101 can define a top end 102 and a bottom end 104, and the topend 102 can be disposed opposite from the bottom end 104. The sidepanels 112 a,b can define lips 114 a,b, respectively, disposed proximateto the top end 102 of the insulated box 110. The side panels 122 a,b candefine lips 124 a,b, respectively, disposed proximate to the top end 102of the insulated box 110. The box 101 can define a box opening 106 atthe top end 102. The box top 190 can be sized and shaped to fit betweenthe lips 114 a,b and the lips 124 a,b to cover the box opening 106 whenthe box 101 is in the closed position. The box top 190 can comprise aninsulated panel 140 which can be substantially identical in constructionto the insulated panels 130 a-d; however in other aspects, the insulatedpanel 140 can differ in construction from the insulated panels 130 a-d.

The insulated panels 130 a-d can be attached to the side panels 112a,b,122 a,b. The insulated panels 130 a,c (130 c shown in FIG. 3 ) canbe respectively attached to the side panels 112 a,b, and the insulatedpanels 130 b,d (130 d shown in FIG. 3 ) can be respectively attached tothe side panels 122 a,b. Each insulated panel 130 a-d can define aborder 158 extending around the respective insulated panel 130 a-d. Anarea encircled by the border 158 can define an insulated portion 161 ofthe respective insulated panel 130.

The border 158 of each insulated panel 130 a-d can define a top seam 156a and a bottom seam 156 b extending outwards from the insulated portion161 of the respective insulated panel 130 a-d. The top seam 156 a can beattached to the adjacent side panel 112 a,b,122 a,b of the box 101proximate the top end 102 of the box 101. In the present aspect, the topseam 156 a of each insulated panel 130 a-d can attach to the lip 114a,b,124 a,b of the adjacent side panel 112 a,b,122 a,b. The bottom seam156 b of each insulated panel 130 a-d can be attached to the adjacentside panel 112 a,b,122 a,b along the bottom end 104 of the box 101. Theseams 156 a,b can be attached by an adhesive such as a glue, cement,epoxy, mastic, double-sided tape, cohesive, or any other suitablematerial, and the seams 156 a,b can secure the insulated panels 130 a-dto the respective adjacent side panels 112 a,b,122 a,b.

The carrying accessory 170 can extend beneath the box 101 to facilitatehand carrying of the box 101. The carrying accessory 170 can define aU-shape. A middle portion 180 can extend beneath the box 101. A firstside portion 172 a can extend upwards from the middle portion 180 andcan be adjacent to the insulated panel 130 a. A second side portion 172b can extend upwards from the middle portion 180 and can be adjacent tothe insulated panel 130 c (shown in FIG. 3 ).

In the present aspect, the carrying accessory 170 can be attached to thebox 101 or the insulated panels 130 a,c such as with an adhesive, suchas a glue, cement, epoxy, mastic, double-sided tape, cohesive, or anyother suitable material. In other aspects, the carrying accessory 170can be mechanically attached, such as with a hook-and-loop fastener,stitching, or staples, and the mechanical attachment of the carryingaccessory 170 can be configured to be selectively attached and detachedfrom the box 101 such as with hook-and-loop fasteners. In other aspects,the carrying accessory 170 may not be attached to the box 101. In someaspects, the side portions 172 a,b can extend upwards adjacent to theinsulated panels 130 b,d. In some aspects, the carrying accessory 170can have four side portions (not shown), and one side portion can bepositioned adjacent to each of the four insulated panels 130 a-d.

The side portions 172 a,b can respectively define handles 178 a,b. Inthe present aspect, handle 178 a can be attached to an end 174 a of thefirst side portion 172 a by a base strip 176 a. Handle 178 b can beattached to an end 174 b of the second side portion 172 b by a basestrip 176 b. The handles 178 a,b can comprise twisted paper rope, andthe handles 178 a,b can be laminated between two layers of therespective base strip 176 a,b. In other aspects, the handles 178 a,b canbe integrally formed with the base strips 176 a,b, and the handles 178a,b and the base strips 176 a,b can comprise a common material. Forexample, the base strips 176 a,b and the handles 178 a,b can comprise aheavy kraft paper, plastic, posterboard, cardboard, or other suitablematerial. In other aspects, the handles 178 a,b can comprise a fibersuch as cotton, hemp, jute, or bamboo fiber.

The base strips 176 a,b can be attached to the respective ends 174 a,bwith an adhesive such as a glue, cement, epoxy, mastic, double-sidedtape, cohesive, or any other suitable material. The ends 174 a,b and thehandles 178 a,b can extend upwards above the box opening 106. In otheraspects, the handles 178 a,b and the ends 174 a,b may not extend abovethe box opening 106, and the handles 178 a,b can be positioned adjacentto the insulated panels 130 b,d. In other aspects, the handles 178 a,bcan have a different shape and can be attached directly to therespective side portions 172 a,b. In some aspects, the handles 178 a,bcan be formed integrally with the respective side portions 172 a,b, forexample, by cutting a hand hole through the respective side portion 172a,b.

FIG. 2 is a perspective view of the modular box assembly 100 of FIG. 1with the box top 190 in an open position. In the open position, the boxtop 190 can be removed from the box opening 106, thereby exposing a boxcavity 206 defined within the box 101. The first pair of opposing sidepanels 112 a,b and the second pair of opposing side panels 122 a,b ofthe box 101 can define the box cavity 206. A pair of shoulders 222 a,bcan extend inwards into the box cavity 206 from each of the side panels122 a,b, as represented by the shoulder 222 b (shoulder 222 a shown inFIG. 3 ). The shoulders 222 a,b are configured to support the box top190 when the box top 190 is positioned between the lips 114 a,b,124 a,bin the closed position. In the closed position, the box top 190 cancover the box opening 106 and enclose the box cavity 206.

In the present, aspect, the box top 190 can comprise the insulated panel140 and a top panel 240. The top panel 240 can be a rigid panel. Theinsulated panel 140 can be attached to the top panel 240 and positionedatop the top panel 240 as shown. In other aspects, the box top 190 canbe flipped, and the insulated panel 140 can be positioned beneath thetop panel 240. In other aspects, the box top 190 can comprise a secondinsulated panel (not shown), and the box top 190 can be insulated onboth sides for added insulation value. In other aspects, the box top 190may not comprise the insulated panel 140, and the top panel 240 can beuninsulated. The top panel 240 can comprise corrugated cardboard in thepresent aspect; however, in other aspects the top panel 240 can becomprise a suitable rigid board material such as wood, plastic, metal,or any other material.

FIG. 3 is a cross-section of the insulated box 110 of FIG. 1 taken alongline 3-3 shown in FIG. 2 , with the carrying accessory 170 and the boxtop 190 removed. As shown, each shoulder 222 a,b can comprise twosub-shoulders 322. The shoulder 222 a can comprise the sub-shoulders 322a,b, and the shoulder 222 b can comprise the sub-shoulders 322 c,d. Thesub-shoulders 322 a-d can be defined by a plurality of first wings 312a-d and a plurality of second wings 324 a-d. The first wings 312 a,b canbe attached at opposite sides of the side panel 112 a, and the firstwings 312 c,d can be attached at opposite sides of the side panel 112 b.The second wings 324 a,b can be attached at opposite sides of the sidepanel 122 a, and the second wings 324 c,d can be attached at oppositesides of the side panel 122 b.

The second wing 324 a can be folded inwards at a hinge 365 a andpositioned adjacent to an inner side surface 326 a defined by the sidepanel 122 a, and the first wing 312 c can be folded at a hinge 370 c andpositioned adjacent to the second wing 324 a. The second wing 324 a andthe first wing 312 c can be secured in position, such as with anadhesive, to form the sub-shoulder 322 a. The second wing 324 b can befolded inwards at a hinge 365 b and positioned adjacent to the innerside surface 326 a, and the first wing 312 a can be folded at a hinge370 a and positioned adjacent to the second wing 324 b. The second wing324 b and the first wing 312 a can be secured in position, such as withan adhesive, to form the sub-shoulder 322 b.

For the sub-shoulder 322 c of shoulder 222 b, the second wing 324 c canbe folded inward at a hinge 365 c and positioned adjacent to an innerside surface 326 b defined by the side panel 122 b. The first wing 312 dcan then be folded at a hinge 370 d and positioned adjacent to thesecond wing 324 c. The first wing 312 d and the second wing 324 c can besecured in position, such as with an adhesive, to form the sub-shoulder322 c. For the sub-shoulder 322 d of shoulder 222 b, the second wing 324d can be folded inward at a hinge 365 d and positioned adjacent to theinner side surface 326 b. The first wing 312 b can then be folded at ahinge 370 b and positioned adjacent to the second wing 324 d. The firstwing 312 b and the second wing 324 d can be secured in position, such aswith an adhesive, to form the sub-shoulder 322 d.

The formation of the sub-shoulders 322 a-d can also secure each sidepanel 112 a,b to each side panel 122 a,b, thereby defining the square orrectangular horizontal cross-section of the box 101. The box 101 canfurther comprise a bottom panel 306. The bottom panel 306 can be a rigidpanel. The bottom panel 306 can be disposed at the bottom end 104 of thebox 101, and the bottom panel 306 can be attached to each of the sidepanels 112 a,b,122 a,b. The bottom panel 306 can further define the boxcavity 206. The box 101 is but one example of a box, and the methodsdiscussed below for insulating the box 101 to form the insulated box 110can be applied to a box of another shape, size, or form.

In the present aspect, the bottom panel 306 can define a center subpanel380 disposed at a center of the bottom panel 306. The center subpanel380 can be substantially rectangular in shape. A center fold line 382can extend between the center subpanel 380 and each side panel 112 a,b,and the center fold line 382 can substantially bisect the bottom panel306, with the exception of within the center subpanel 380. The centerfold line 382 can also bisect each side panel 112 a,b, as shown andfurther described with respect to FIG. 7 . Four corner fold lines 384a-d can extend between the corners of the center subpanel 380 and thehinges 370 a-d. The corner fold line 384 a can extend from the hinge 370a to the center subpanel 380. The corner fold line 384 b can extend fromthe hinge 370 b to the center subpanel 380. The corner fold line 384 ccan extend from the hinge 370 c to the center subpanel 380. The cornerfold line 384 d can extend from the hinge 370 d to the center subpanel380.

A plurality of V-shaped fold lines 386 a-f can extend between the hinges370 a-d and the center fold line 382. The V-shaped fold lines 386 a-ccan each extend from the hinge 370 a to center fold line 382 and then tothe hinge 370 b. The V-shaped fold lines 386 a-c can be defined betweenthe corner fold lines 384 a and 384 b. The V-shaped fold lines 386 d-fcan each extend from the hinge 370 c to center fold line 382 and then tothe hinge 370 d. The V-shaped fold lines 386 d-f can be defined betweenthe corner fold lines 384 c and 384 d. The center subpanel 380, thecenter fold line 382, the corner fold lines 384 a-d, and the V-shapedfold lines 386 a-f can cooperate to collapse the insulated box 110 andto provide the bottom panel 306 with a truncated pyramidal shape whencollapsed, as further discussed below with respect to FIG. 8 .

The box 101 of the insulated box 110 can be clad with the insulatedpanels 130 a-d. The insulated panel 130 a can be attached to an outerside surface 328 a defined by the side panel 122 a. The insulated panel130 b can be attached to an outer side surface 314 a defined by the sidepanel 112 a. The insulated panel 130 c can be attached to an outer sidesurface 328 b defined by the side panel 122 b. The insulated panel 130 dcan be attached to an outer side surface 314 b defined by the side panel112 b. In the present aspect, the box 101 can be externally clad withthe insulated panels 130 a-d, however in other aspects, the box 101 canbe internally clad, both internally and externally clad, or a mixedarrangement of partially internally clad and partially externally cladwith insulated panels 130.

In the present aspect, each insulated panel 130 a-d can comprise aninsulation batt 350, a first sheet 352, and a second sheet 354. Theinsulation batt 350 can be encapsulated in a panel cavity 351 definedbetween the first sheet 352 and the second sheet 354. The insulationbatt 350 can be encapsulated by the border 158 which can extend around aperimeter 359 of the insulation batt 350, thereby sealing the panelcavity 351. The panel cavity 351 containing the insulation batt 350 candefine the insulated portion 161 of the respective insulated panel 130a-d. The border 158 can be a seam formed by attaching a perimeterportion of the first sheet 352 which overhangs the perimeter 359 of theinsulation batt 350 with a perimeter portion of the second sheet 354which also overhangs the perimeter 359 of the insulation batt 350. Thefirst sheet 352 can be attached to the second sheet 354 with an adhesivesuch as a glue, cement, epoxy, mastic, cohesive, double-side tape orother suitable adhesive to form the border 158. In some aspects, theborder 158 can be formed by mechanically fastening the first sheet 352to the second sheet 354, such as by stapling, stitching, or any othersuitable method of fastening.

The border 158 can further define a first side seam 356 a and a secondside seam 356 b. In the present aspect, the first side seam 356 a andthe second side seam 356 b can be vertically oriented seams. The firstside seam 356 a and the second side seam 356 b of the border 158 can befolded inwards and disposed between the insulation batt 350 of theinsulated portion 161 and the outer side surface 328 a,b of therespective side panels 122 a,b or the outer side surfaces 314 a,b of therespective side panels 112 a,b. The first side seam 356 a and the secondside seam 356 b can be attached to the adjacent side panel 112 a,b,122a,b, thereby further securing the insulated panel 130 a-d to theadjacent side panel 112 a,b,122 a,b and enclosing the insulation batt350 between the first sheet 352 and the adjacent side panel 112 a,b,122a,b. By folding the first side seam 356 a and the second side seam 356 binwards, the insulation batt 350 and the insulated portion 161 canextend completely across or nearly completely across the width of theadjacent side panel 112 a,b,122 a,b without leaving the first side seam356 a and the second side seam 356 b sticking outwards beyond the sidepanel 112 a,b,122 a,b. This configuration can provide full insulation ornearly full insulation over the width of the adjacent side panel 112a,b,122 a,b.

With the first side seam 356 a and the second side seam 356 b foldedinwards, the first sheet 352 can be attached to the respective adjacentside panel 112 a,b,122 a,b with an adhesive such as a glue, cement,epoxy, mastic, double-sided tape, cohesive, or other suitable material.A portion of the second sheet 354 extending between the first side seam356 a and the second side seam 356 b can also be in facing contact withthe adjacent side panel 112 a,b,122 a,b and can optionally be attachedwith the adhesive. In other aspects, the insulated panels 130 a-d maynot comprise the second sheet 354, and either the insulation batt 350can be in facing contact with the respective adjacent side panel 112a,b,122 a,b, or the first sheet 352 can fully encapsulate the insulationbatt 350.

FIG. 4 is a cross-section of the modular box assembly 100 of FIG. 1taken along line 4-4 shown in FIG. 2 . In the present view, the carryingaccessory 170 has been removed. The modular box assembly 100 can furthercomprise an insulated cavity panel 430 which can be disposed within thebox cavity 206. The insulated cavity panel 430 can be constructedsimilar to the insulated panels 130 a-d,190; however, in the presentaspect, the insulated cavity panel 430 can be a loose panel. Theinsulated portion 161 of the insulated cavity panel 430 can be shapedand sized complimentary to the horizontal cross-section of the box 101in order to provide a close fit within the box cavity 206.

As shown, the insulated cavity panel 430 can divide the box cavity 206into a first sub-compartment 406 a and a second sub-compartment 406 b.In the present aspect, the insulated cavity panel 430 can behorizontally oriented, and the first sub-compartment 406 a can be anupper sub-compartment while the second sub-compartment 406 b can be alower sub-compartment. In other aspects, the insulated cavity panel 430can be vertically oriented to divide the box cavity 206 intoside-by-side compartments. In some aspects, the insulated box 110 cancomprise multiple cavity panels 430 disposed within the box cavity 206to divide the box cavity 206 into more than two compartments or noinsulated cavity panels 430 so that the box cavity 206 is a singlecompartment. Dividing the box cavity 206 into sub-compartments can bedesirable in order to package both hot and cold contents in the sameinsulated box 110 or other contents that should be stored at differenttemperatures.

In the present aspect, the bottom panel 306 can be uninsulated.Optionally, the insulated cavity panel 430 can be placed atop the bottompanel 306 to provide insulation for the bottom end 104 of the insulatedbox 110. In other aspects, the insulated box 110 can further compriseanother insulated panel 130 (not shown) attached internally orexternally to the bottom panel 306. In aspects in which the box top 190can be uninsulated, the insulated cavity panel 430 can be positionedadjacent to the box top 190 to provide insulation for the top end 102 ofthe insulated box 110. In some aspects, the bottom panel 306 can beinsulated and the insulated cavity panel 430 can be placed atop thebottom panel 306 in order to provide additional insulation for example.In some aspects, the modular box assembly 100 can comprise multipleinsulated cavity panels 430 positioned within the box cavity 206. Inother aspects, the modular box assembly 100 can comprise any or all ofthe insulated cavity panel 430, a bottom insulated panel 2130 (shown inFIG. 21 ), and a divider panel 2230 (shown in FIG. 22 ).

The bottom seam 156 b and the top seam 156 a of the border 158 of eachinsulated panel 130 a-d can extend outwards from the perimeter 359 ofthe insulation batt 350 and the insulated portion 161. As previouslydiscussed, the bottom seams 156 b and the top seams 156 a can beattached to the respective adjacent side panel 112 a,b,122 a,b with theadhesive in order to secure the insulated panels 130 a-d, to the box 101proximate the top end 102 and the bottom end 104. In such aspects, thesecond sheet 354 can be attached to the adjacent side panel 112 a,b,122a,b, and the first sheet 352 may not contact the adjacent side panel 112a,b,122 a,b at the bottom seam 156 b and the top seam 156 a; however,the insulation batt 350 remains enclosed between the first sheet 352 andthe adjacent side panel 112 a,b,122 a,b. Optionally, portions of thesecond sheet 354 disposed between the top seams 156 a and the bottomseam 156 b can also be attached to the respective adjacent side panel112 a,b,122 a,b with the adhesive.

The outward extending top seams 156 a can leave the lips 114 a,b,124 a,buninsulated; however, because the box top 190 rests below the boxopening 106 on the shoulders 222 a,b (should 222 b shown in FIG. 3 ),the top end 102 of the insulated box 110 can remain fully insulated.Similarly, the bottom seams 156 b can leave a portion of the side panels112 a,b,122 a,b proximate the bottom panel 306 uninsulated. However, inaspects in which the insulated cavity panel 430 can be positioned atopthe bottom panel 306, the insulated cavity panel 430 can fully insulatethe bottom end 104 of the insulated box 110. In other aspects, either orboth of the bottom seams 156 b and top seams 156 a can be folded inwardtowards the insulation batt 350 and the insulated portion 161, and theinsulation batt 350 can fully cover the height of the side panels 112a,b,122 a,b.

The outwardly extended bottom seams 156 b can define a bottom taper 458extending around the insulated box 110 proximate the bottom end 104. Thebottom taper 458 can cooperate with the lips 114 a,b,124 a,b to securelystack multiple insulated boxes 110 on top of one another. The lips 114a,b,124 a,b of a lower insulated box of the stack of insulated boxes candeflect outwards allowing the bottom taper 458 of an upper insulated boxto nest between the lips 114 a,b,124 a,b and atop the box top 190 of thelower insulated box. By nesting between the lips 114 a,b,124 a,b, thelips 114 a,b,124 a,b can prevent the upper insulated box from slidingsideways off the top end 102 of the lower insulated box. The insulatedboxes 110 can also be conveyable, such as on a conveyor belt, and theinsulated boxes 110 can be rigid and strong enough to resist collapse onthe conveyor belt. In other aspects, the lips 114 a,b,124 a,b can beconfigured to be flush with the top panel 240 of the box top 190 whenthe box top 190 is in the closed position.

FIG. 5 is a perspective view of a method of manufacturing for aninsulated panel 510. The method can apply to the manufacture of theinsulated panels 130 a-d,140,430 or an insulation wrap 1730 (shown inFIG. 17 ). In a step 501, the insulation batt 350 can be positionedbetween the first sheet 352 and the second sheet 354. The first sheet352 and the second sheet 354 can be sized and shaped complimentary toeach other; however in some aspects, the sheets 352,354 can differ insize and shape. The insulation batt 350 and the sheets 352,354 can eachbe flat and substantially planar before assembly. In the present aspect,the insulation batt 350 can be approximately ⅜″ thick; however thisthickness is not limiting. The thickness can range from 1/16″ to over 2″with a preferred range of ¼″ to ½″. Also, as disclosed in at least oneof the provisional applications incorporated by reference below, eachbatt used within the modular box assembly 100 may be of equal thickness,or may be of unequal thicknesses. A starting batt may be splitlongitudinally to provide two, three, or more partial thickness batts.

The first sheet 352 can define a first outer edge 552, and a portion ofthe first sheet 352 proximate the first outer edge 552 can define afirst perimeter portion 542. The second sheet 354 can define a secondouter edge 554, and a portion of the second sheet 354 proximate thesecond outer edge 554 can define a second perimeter portion 544. Thesheets 352,354 can be sized to overhang the insulation batt 350 on allsides with the first perimeter portion 542 and the second perimeterportion 544 extending beyond the perimeter 359 of the insulation batt350. The first perimeter portion 542 can encompass a first interiorportion 536 of the first sheet 352, and the second perimeter portion 544can encompass a second interior portion 538 of the second sheet 354. Theinterior portions 536,538 can be sized and shaped complimentary to theinsulation batt 350.

Surfaces of the sheets 352,354 facing one another can be treated with anadhesive 530 such as a cohesive. In various aspects, the adhesive can bea glue, epoxy, cement, double-sided tape, or other suitable adhesive.The surfaces can be entirely treated with the adhesive 530 orselectively treated with the adhesive 530. In the aspect shown, theperimeter portions 542,544 can be selectively treated with the adhesive530. In some aspects, the insulation batt 350 can also be adhered to theinterior portions 536,538 of the sheets 352,354.

In a step 502, the sheets 352,354 can be aligned and positioned infacing engagement wherein the first perimeter portion 542 can beattached to the second perimeter portion 544 by the adhesive 530. Theinsulation batt 350 can be aligned between the interior portions536,538. Attaching the perimeter portions 542,544 can form the border158 of the insulated panel 510 around the perimeter 359 of theinsulation batt 350. As depicted in step 502, the bottom seam 156 b hasbeen formed, the first side seam 356 a and the second side seam 356 bare partially formed, and the top seam 156 a is yet to be formed.

The border 158 can seal the insulation batt 350 within the panel cavity351 defined between the interior portions 536,538 of the sheets 352,354,respectively. Portions of the insulated panel 510 containing theinsulation batt 350 can define the insulated portion 161 of theinsulated panel 510. In some aspects, the insulation batt 350 can bealigned off-center from the sheets 352,354 wherein the border 158 canextend outwards further in some areas than others. In some aspects, thefirst side seam 356 a, the second side seam 356 b, the bottom seam 156b, and the top seam 156 a can define different widths from one another.For example and without limitation, the first side seam 356 a can extendoutwards from the insulation batt 350 further than the bottom seam 156 bor vice versa.

In a step 503, the first perimeter portion 542 has been fully attachedto the second perimeter portion 544, thereby forming the completedborder 158. Each of the first side seam 356 a, the second side seam 356b, the bottom seam 156 b, and the top seam 156 a are fully formed.Manufacturing of the insulated panel 510 is thus completed; however insome aspects, the method can comprise additional steps such as cuttingslots into the border 158. The border 158 can fully encapsulate theinsulation batt 350 within the panel cavity 351; however in someaspects, the insulation batt 350 may not be fully encapsulated. In someaspects, the insulation batt 350 can define a complex shape which cancomprise curves, notches, cutouts, or other features which can bereflected by complimentary shapes of the border 158 and the insulatedportion 161.

In other aspects, the border 158 may not fully encompass and encapsulatethe insulation batt 350. In some aspects, some portions of the perimeter359 may be exposed at an unfinished side or a cutout of the border 158.In some aspects, the insulated panel 510 may not define the border 158on any portion of the perimeter of the insulated panel 510, and theentire perimeter can define an unfinished edge. In such aspects, theinsulated panel 510 can comprise pre-laminated paper and each of thesheets 352,354 can be attached in facing contact with the insulationbatt 350 with, for example and without limitation, an adhesive. In someaspects in which the insulated panel 510 defines the border 158, theinsulation batt 350 can also be attached in facing contact with one orboth of the sheets 352,354. In some aspects, the pre-laminated paper canbe provided in a roll, and the insulated panels 510 can be cut to sizefrom the roll. In other aspects, the first sheet 352 and the secondsheet 354 can be halves of a single sheet (not shown) which can befolded substantially in half. In such aspects, the insulation batt 350can be encapsulated between the two halves of the single sheet. In otheraspects, the second sheet 354 can be a board (not shown), such as apiece of cardboard, and the insulation batt 350 can be encapsulatedbetween the first sheet 352 and the board.

In some aspects, the second sheet 354 can be a board 2154 (shown in FIG.21 ). In such applications, the board 2154 can be rigid and the firstsheet 352 can laminate and encapsulate the insulation batt 350 to theboard 2154 to provide a rigid insulated panel, such as the bottominsulated panel 2130.

FIGS. 6A-C show perspective views of a method for attaching theinsulated panel 130 a to the side panel 122 a. In FIG. 6A, the insulatedpanel 130 a is shown partially attached to the side panel 122 a. In thepresent aspect, the insulated panel 130 a and the adjacent insulatedpanel 130 b can be separate and isolated insulation panels 130 which arenot connected together. By using separate insulated panels 130,manufacturing stress around corners of the insulated box 110 can bereduced during assembly of the insulated box 110, thereby reducing thelikelihood of ripping or tearing the insulated panels 130 duringassembly. The insulated panel 130 a can be positioned adjacent to theside panel 122 a, and the bottom seam 156 b can be attached to aperimeter area 656 of the outer side surface 328 a. The perimeter area656 can extend around the edges of the side panel 122 a. Specifically,the bottom seam 156 b can be attached to a bottom portion (not shown) ofthe perimeter area 656 extending along the bottom end 104 of the sidepanel 122 a. The perimeter area 656 can also define a first portion 658a and a second portion 658 b extending upwards from the bottom portiontowards a top portion 658 c. The top portion 658 c can extend along thelip 124 a proximate the top end 102 of the side panel 122 a.

The bottom seam 156 b of the border 158 can extend outwards from theinsulated portion 161 of the insulated panel 130 a, and the second sheet354 of the bottom seam 156 b can be attached to the outer side surface328 a. In other aspects, the bottom seam 156 b can be folded inwardstowards the insulation batt 350 (not shown) encapsulated within theinsulated portion 161. The bottom seam 156 b can be attached in facingcontact with the side panel 122 a by an adhesive such as a glue, epoxy,cement, mastic, or any other suitable adhesive. In other aspects, thebottom seam 156 b can be mechanically attached to the side panel 122 asuch as with a hook-and-loop fastener, stitching, or staples, or othersuitable fasteners. In the present aspect, the first side seam 356 a andthe second side seam 356 b (shown in FIG. 6B) can be folded inwardstowards the insulation batt 350 (not shown) encapsulated within theinsulated portion 161. The first side seam 356 a can be attached to thebottom portion (not shown) at an intersection between the bottom portionand the first portion 658 a of the perimeter area 656. The second sideseam 356 b can be attached to the bottom portion (not shown) at anintersection between the bottom portion and the second portion 658 b ofthe perimeter area 656.

In FIG. 6B, the insulated panel 130 a is shown with the bottom seam 156b attached to the side panel 122 a, and the first side seam 356 a andthe second side seam 356 b partially attached to the first portion 658 aand the second portion 658 b of the perimeter area 656, respectively.The first sheet 352 of the first side seam 356 a and the second sideseam 356 b can be attached in facing contact to the perimeter portion656 of the outer side surface 328 a by an adhesive such as a glue,epoxy, cement, mastic, double-sided tape, cohesive, or other suitableadhesive. In other aspects, the first sheet 352 of the first side seam356 a and the second side seam 356 b can be mechanically attached to theperimeter portion 656 of the outer side surface 328 a, such as with ahook-and-loop fastener, stitching, or staples, or other suitablefasteners. In the aspect shown, the insulated panel 130 a is shown asfirst attached proximate the bottom end 104 and then subsequentlyattached upwards along the first side seam 356 a and the second sideseam 356 b towards the top end 102; however, this sequence and directionof attachment are not limiting. The insulated panel 130 a can first beattached at the first side seam 356 a, the second side seam 356 b, orthe top seam 156 a and further attached in a sideways or downwardsdirection, or in any other suitable sequence. In some aspects, thesecond sheet 354 of the insulated portion 161 can also be attached tothe outer side surface 328 a by an adhesive such as a glue, epoxy,cement, mastic, or any other suitable adhesive.

FIG. 6C shows the insulated panel 130 a completely attached to the sidepanel 122 a. The first side seam 356 a (shown in FIG. 6B) can becompletely attached to the first portion 658 a (shown in FIG. 6B) of theperimeter area 656 (shown in FIG. 6B) from the bottom end 104 to the topend 102. The second side seam 356 b (shown in FIG. 6B) can be completelyattached to the second portion 658 b (shown in FIG. 6B) of the perimeterarea 656 (shown in FIG. 6B) from the bottom end 104 to the top end 102.The top seam 156 a can be fully attached to the top portion 658 c (shownin FIG. 6B) by an adhesive such as a glue, epoxy, cement, mastic,double-sided tape, cohesive, or any other suitable adhesive. In otheraspects, the top seam 156 a can be mechanically attached to the topportion 658 c, such as with a hook-and-loop fastener, staples, orstitching, or other suitable fasteners.

One method for attaching the insulated panel 130 a to the side panel 122a shown in FIGS. 6A-C can apply to any of the insulated panels 130a-d,140 and any of the adjacent panels 112 a,b,122 a,b,240. The methodcan also be used to attach the insulated panels 130 a-d to an innersurface, such as inner side surfaces 326 a,b, within the box cavity 206.The method is demonstrated on the assembled box 101, and the method isexemplary and not limiting. The various panels 112 a,b,122 a,b,306 ofthe box 101 can also be clad with individual insulated panels 130 a-dprior to assembly of the box 101. For example, the insulated panels 130a-d, can be attached to the respective panels 112 a,b,122 a,b of anunfolded box blank 710 (shown in FIG. 7 ). It can be desirable to attachthe insulated panels 130 a-d to the unfolded box blank 710 prior toassembly in order to reduce mechanical handling of the box 101. Inanother aspect, the insulated box 110 can be formed by wrapping theinsulation wrap 1730 around the box 101 as described relative to FIG. 17.

FIG. 7 is a top view of the box blank 710 which can be assembled to formthe box 101 of the insulated box 110. The box blank 710 can furtherdefine four corner fold lines 750 a-d, such as a scored crease. In otheraspects, the box blank 710 can define cuts in place of the corner foldlines 750 a-d. A first corner fold line 750 a can extend outwards fromthe bottom panel 306 to separate the first wing 312 a from the secondwing 324 b. A second corner fold line 750 b can extend outwards from thebottom panel 306 to separate the first wing 312 b from the second wing324 d. A third corner fold line 750 c can extend outwards from thebottom panel 306 to separate the first wing 312 c from the second wing324 a. A fourth corner fold line 750 d can extend outwards from thebottom panel 306 to separate the first wing 312 d from the second wing324 c. In the present aspect, the adjacent wings 312 a-d,324 a-d can behingedly connected by the corner fold lines 750 a-d. In other aspects,the corner fold lines 750 a-d can be cuts which separate the adjacentwings 312 a-d,324 a-d.

The box blank 710 can define a first length fold line 712 a and a secondlength fold line 712 b extending from the side panel 112 a to the sidepanel 112 b. The first length fold line 712 a can facilitate folding ofthe first wing 312 a relative to the side panel 112 a, the side panel122 a relative to the bottom panel 306, and the first wing 312 crelative to the second side panel 112 b. The second length fold line 712b can facilitate folding of the first wing 312 b relative to the sidepanel 112 a, the side panel 122 b relative to the bottom panel 306, andthe first wing 312 d relative to the side panel 112 b.

The box blank 710 can further define a first width fold line 722 a and asecond width fold line 722 b. The width fold lines 722 a,b can bedefined substantially perpendicular to the length fold lines 712 a,b.The first width fold line 722 a can facilitate folding of the secondwing 324 a relative to the side panel 122 a, the side panel 112 brelative to the bottom panel 306, and the second wing 324 c relative tothe side panel 122 b. The second width fold line 722 b can facilitatefolding of the second wing 324 b relative to the side panel 122 a, theside panel 112 a relative to the bottom panel 306, and the second wing324 d relative to the side panel 122 b.

The center fold line 382 can extend across and bisect each side panel112 a,b. The center fold line 382 facilitates each of the side panels112 a,b folding inwards about the center fold line 382 and towards thebottom panel 306 to facilitate collapsing the insulated box 110 as shownin FIG. 8 .

In some aspects, the insulated panels 130 a-d can be attached to theside panels 112 a,b,122 a,b to the unfolded box blank 710 prior toassembly. In other aspects, a single insulated panel 130 a,b can beattached to the unfolded box blank 710 to cover the side panels 112a,b,122 a,b, and in some aspects, the bottom panel 306 as well. In someaspects, the entire unfolded box blank 710 can be covered by a singleinsulated panel.

FIG. 8 is a perspective view of the insulated box 110 of FIG. 1 in acollapsed configuration. In the present view, the carrying accessory 170is removed to better show the details of the bottom panel 306. As theinsulated box 110 collapses, the side panels 122 a,b (side panels 122a,b shown in FIG. 1 ) move inwards together and towards one another, andthe side panels 112 a,b fold inwards towards one another (side panels112 a,b shown in FIG. 1 ). The V-shaped fold lines 386 a-f (V-shapedfold lines 386 e,f shown in FIG. 7 ) cooperate to transition the bottompanel 306 from a substantially planar shape to the truncated pyramidalshape. In the truncated pyramidal shape, the center subpanel 380 extendsoutwards and away from the side panels 112 a,b and the side panels 122a,b (shown in FIG. 7 ). Exerting a force upon the center subpanel 380,such as by pushing the box 101 against the ground can cause theinsulated box 110 to self-expand into an expanded configuration (shownin FIG. 1 ) with a substantially rectangular prism shape. Theself-expanding action can be desirable to allow for quick and easyreconfiguration of the insulated box 110, unlike many boxes which mustbe folded and taped together. The insulated boxes 110 can be shipped andstored in the collapsed configuration for space-efficient packing, and auser can simply press upon the center subpanel 380, such as by pressingthe center subpanel 380 against the ground, and the insulated box 110can reconfigure to the expanded configuration.

FIG. 9 is a top view of the carrying accessory 170 of FIG. 1 . Aspreviously described, the carrying accessory 170 can be configured toextend beneath the insulated box 110 (shown in FIG. 1 ) to facilitatehand carrying of the insulated box 110. The carrying accessory 170 candefine two pairs of fold lines 910 a,b. A first pair of fold lines 910 acan be defined between the first side portion 172 a and the middleportion 180, and a second pair of fold lines 910 b can be definedbetween the second side portion 172 b and the middle portion 180. Thefold lines of each pair of fold lines 910 a,b can be placed closelytogether, such as an inch apart or less, and can be substantiallyparallel to one another. The pairs of fold lines 910 a,b configure thecarrying accessory 170 to closely conform to the bottom taper 458 (shownin FIG. 3 ) of the bottom end 104 of the insulated box 110. The middleportion 180 of the carrying accessory 170 can also define a pair ofmiddle fold lines 912. The middle fold lines 912 can configure thecarrying accessory 170 to closely conform to the truncated pyramidalshape of the bottom panel 306 (shown in FIG. 8 ) when the insulated box110 is in the collapsed configuration as shown in FIG. 8 . In otheraspects each or any of the pairs of fold lines 910 a,b and 912 can besubstituted with single fold lines as desired.

FIG. 10 is a perspective view of the modular box assembly 100 comprisingthe insulated box 110 of FIG. 1 and another aspect of a box top 190 inaccordance with another aspect of the present disclosure. In the presentaspect, the box top 190 can be a tray top 1090. The tray top 1090 cancomprise a top panel 1092 and four side panels, as represented by sidepanels 1094 a,b, extending down from the top panel 1092. The tray top1090 can be configured to fit over the top end 102 of the box 101 (shownin FIG. 1 ). The side panels 1094 can fit over the lips 114 a,b,124 a,b(shown in FIG. 1 ) to enclose the box cavity 206 (shown in FIG. 2 ).

FIG. 11 is a perspective view of the modular box assembly 100 comprisingthe insulated box 110 of FIG. 1 and another aspect of a box top 190 inaccordance with another aspect of the present disclosure. In the presentaspect, the box top 190 can be a handle panel 1190. The handle top 1190can comprise a top panel 1192 and a pair of side panels 1196 a,battached at opposite sides of the top panel 1192. In the present aspect,the top panel 1192 can be positioned between the lips 114 a,b,124 a,b ofthe box 101, and the side panels 1196 a,b can be positioned adjacent tothe side panels 122 a,b. The side panels 1196 a,b can be hingedlyattached to the top panel 1192. The handle top 1190 can further comprisea pair of side tabs 1396 a,b (shown in FIG. 13 ) which can be attachedto the top panel 1192 and which can extend downwards into the box cavity206 (shown in FIG. 2 ), adjacent to the side panels 112 a,b. In someaspects, the side tabs of the handle top 1190 can be glued to either theinside or the outside of the side panels 112 a,b to secure the handletop 1190 to the insulated box 110. In other aspects, the handle top 1190can be secured to the insulated box 110 by tape, banding, a strap, orother restraint mechanism.

A handle loop 1188 a,b can be attached to each side panel 1196 a,b,respectively, by a tape strip 1198 a,b. In the present aspect, the tapestrips 1198 a,b can extend completely around the respective side panel1196 a,b to secure the handle loop 1188 a,b to the side panel 1196 a,b.In the present aspect, the handle loops 1188 a,b can be rope loops. Thehandle loops 1188 a,b can allow a user to carry the modular box assembly100. In the present aspect, each handle loop 1188 a,b can comprise arope, such as a paper rope, a hemp rope, a manila rope, a cotton rope, aflax rope, a plastic rope, or any other suitable type of rope.

In the present aspect, the top panel 1192 can further comprise a pair offolding tabs 1194 a,b. The folding tabs 1194 a,b can cover a pair ofhand holes 1195 a,b, respectively. The folding tabs 1194 a,b can behingedly connected to the top panel 1192, and the folding tabs 1194 a,bcan be pressed inwards towards the box cavity 206. With the folding tabs1194 a,b pressed inwards, a user can put a finger or fingers througheach of the hand holes 1195 a,b to pick up the modular box assembly 100.In some aspects, the hand holes 1195 a,b can be positioned close enoughtogether that a user can insert a thumb through a first of the handholes 1195 a,b and a finger through the second of the hand holes 1195a,b to pick up the modular box assembly 100 with one hand. In someaspects, the handle top 1190 can comprise the handle loops 1188 a,b butmay not comprise the folding tabs 1194 a,b or define the hand holes 1195a,b. In other aspects, the handle top 1190 can comprise the folding tabs1194 a,b and define the hand holes 1195 a,b but may not comprise thehandle loops 1188 a,b.

FIG. 12 is a perspective view of the modular box assembly 100 comprisingthe insulated box 110 of FIG. 1 and another aspect of a box top 190 inaccordance with another aspect of the present disclosure. The box top190 can be a zipper top 1290. The zipper top 1290 can comprise a toppanel 1292 and a pair of side panels 1294, as represented by the sidepanel 1294 b. The side panels 1294 can be hingedly attached to the toppanel 1292. In the present aspect, the side panels 1294 can overlaps thelips 124 a,b of the side panels 122 a,b of the insulated box 110. Theside panels 1294 can be attached to the side panels 122 a,b by anadhesive, such as a glue, mastic, epoxy, cement, double-sided tape, orany other suitable material. In the present aspect, a strip of adhesive(not shown) can be covered by a backing strip (not shown), and thebacking strip can be removed to adhere the side panels 1294 to the sidepanels 122 a,b. The zipper top 1290 can further comprise a pair of tabs(not shown) which can be inserted into the box cavity 206 (shown in FIG.2 ) and positioned adjacent to the side panels 112 a,b (side panel 112 bshown in FIG. 1 ). In other aspects, the tabs can be disposed externalto the side panels 112 a,b, similar to the side panels 1294. The tabscan be attached to the side panels 112 a,b by the adhesive or theadhesive strip, and the tabs can seal the box cavity 206.

The top panel 1292 can define a zipper 1280 which can be defined by aperforations extending around the zipper 1280. The zipper 1280 canextend across the top panel 1292 and divide the top panel 1292 into afirst top panel portion 1296 a and a second top panel portion 1296 b.The zipper 1280 can be divided into a first zipper portion 1284 a and asecond zipper portion 1284 b by a center perforation line 1282. A usercan press inwards on the center perforation line 1282 to separate thefirst zipper portion 1284 a from the second zipper portion 1284 b. Eachzipper portion 1284 a,b can then be ripped out of the top panel 1292along the perforations, thereby detaching the first top panel portion1296 a from the second top panel portion 1296 b. With the top panelportions 1296 a,b detached, the top panel 1292 can be opened to allowaccess to contents within the box cavity 206.

FIG. 13 is a top view of another aspect of the handle top 1190 inaccordance with another aspect of the present disclosure. In the presentaspect, the handle top 1190 may not define the folding tabs 1194 a,b andthe hand holes 1195 a,b of the aspect of the handle top 1190 of FIG. 11. The side panel 1196 a can be attached at a first side edge 1394 a ofthe top panel 1192 by a tape strip 1393 a and a tape strip 2192 a (shownin FIG. 21 ) attached at opposite sides of the side panel 1196 a and thetop panel 1192. An inner edge 1392 a of the side panel 1196 a can bespaced apart from the first side edge 1394 a, and the tape strips 1393a,2192 a can define a living hinge 1310 a between the side panel 1196 aand the top panel 1192. The side panel 1196 b can be attached at asecond side edge 1394 b of the top panel 1192 by a tape strip 1393 b anda tape strip 2192 b (shown in FIG. 21 ) attached at opposite sides ofthe side panel 1196 a and the top panel 1192. An inner edge 1392 b ofthe side panel 1196 b can be spaced apart from the second side edge 1394b, and the tape strips 1393 b,2192 b can define a living hinge 1310 bbetween the side panel 1196 b and the top panel 1192.

The living hinges 1310 a,b formed by the tape strips 1393 a,b,2192 a,bcan be more flexible than hinges defined into the top panel 1192, suchas by a scored crease line. Hinges defined by a scored crease line candemonstrate positional memory which can resist folding completely inhalf, thereby preventing the side panels 1196 a,b from resting flatagainst the top panel 1192. With the living hinges 1310 a,b, the sidepanels 1196 a,b and handle loops 1188 a,b can lie flat on the top panel1192 which can be desirable for storage or stacking, for example. Inother aspects, the side panels 1196 a,b can be attached directly to thetop panel 1192 by hinges defined by scored crease lines.

The handle loop 1188 a can define a handle portion 1360 a and two baseportions 1362 a,b. The base portions 1362 a,b of the handle loop 1188 acan be laminated to the side panel 1196 a by the tape strips 1393 a,2192 a, thereby attaching the handle loop 1188 a to the side panel 1196a. The handle loop 1188 b can define a handle portion 1360 b and twobase portions 1362 c,d. The base portions 1362 c,d of the handle loop1188 b can be laminated to the side panel 1196 b by the tape strips 1393b, 2192 b, thereby attaching the handle loop 1188 b to the side panel1196 b.

In other aspects, the base portions 1362 a,b,c,d can be laminated inanchor strips (not shown) which can be laminated to the side panels 1196a,b by the tape strips 1393 a,b,2192 a,b. The anchor strips can provideincreased surface area for the tape strips 1393 a,b,2192 a,b to adhereto. In some aspects, the anchor strip can extend between the respectivebase portion pairs 1362 a,b and 1362 c,d; however in other aspect, eachbase portion 1362 a,b,c,d can be laminated in a separate anchor strip.

The side tabs 1396 a,b can be attached to opposite ends of the top panel1192. The side tab 1396 a can be attached by a hinge 1398 a, and theside tab 1396 b can be attached by a hinge 1398 b. In the presentaspect, hinges 1398 a,b can be defined by a scored line which canfacilitate folding relative to the top panel 1192. The side tab 1396 acan be inset from the first side edge 1394 a by a side tab shoulder 1395a and inset from the second side edge 1394 b by a side tab shoulder 1395d. The side tab 1395 b can be inset from the first side edge 1394 a by aside tab shoulder 1395 b and inset from the second side edge 1394 b by aside tab shoulder 1395 c. The side tabs 1396 a,b can be inset from theside edges 1394 a,b to provide clearance for the side tabs 1396 a,b tofit along the side panels 112 a,b (shown in FIG. 2 ) and between theshoulders 222 a,b (shown in FIG. 2 ).

In the present aspect, the handle top 1190 can be uninsulated; howeverin other aspects, the top panel 1192 can be insulated. For example, insome aspects, the top panel 1192 can comprise the insulated panel 140(shown in FIG. 1 ) which can be attached to a top or a bottom surface ofthe top panel 1192, similar to the box top 190 of FIG. 1 .

FIG. 14 is a perspective view of another aspect of the modular boxassembly 100 comprising the box 101 of FIG. 1 and the handle top 1190 ofFIG. 13 . The handle top 1190 can be positioned to cover the box opening106. In the present aspect, the lips 114 a,b,124 a,b (lips 124 a,b shownin FIG. 1 ) can extend upwards from the shoulders 222 a,b (shown in FIG.3 ) by a height equal to a thickness of the top panel 1192 such that thetop panel 1192 rests flush with the lips 114 a,b,124 a,b. In otheraspects, such as the aspect of FIG. 1 , the lips 114 a,b,124 a,b canextend upwards beyond the top panel 190 (shown in FIG. 1 ).

Tape strips 1410 a,b can extend from the side panel 112 a, over the toppanel 1192, and down the side panel 112 b to secure the top panel 1192to the box 101. The tape strip 1410 a can be positioned proximate to theside panel 1196 a of the handle top 1190, and the tape strip 1410 b canbe positioned proximate to the side panel 1196 b of the handle top 1190to prevent the side panels 1196 a,b from pulling away from the boxopening 106 when the handle loops 1188 a,b are held by a user 1400.

Additionally tape strips 1420, as represented by tape strip 1420 b, canattach the side panels 1196 a,b to the side panels 122 a,b (side panel122 a shown in FIG. 1 ). As shown, tape strip 1420 b can define a firstportion 1422 a and a second portion 1422 b. The first portion 1422 a ofthe tape strip 1420 b can be attached to the side panel 122 b, and thesecond portion 1422 b of the tape strip 1420 b can be attached to theside panel 1196 b to prevent the side panel 1196 b from pulling awayfrom the box opening 106, particularly when the box 101 contains heavycontents. The tape strips 1420 can transfer a load from the handle loops1188 a,b to the side panels 122 a,b. In other aspects, the handle top1190 can be secured to the box 101 by a different method or a differentarrangement of tape strips 1410 a,b,1420 b.

FIG. 15 is a perspective view of an inner box 1500, and FIG. 16 is a topview of an inner box blank 1600 of the inner box 1500. The inner boxblank 1600 can comprise a center panel 1610, a pair of side flap panels1618 a,b attached at opposite ends of the center panel 1610, and a firstlocking panel 1614 and a second locking panel 1616 disposed at oppositeends of the center panel 1610. Each side flap panel 1618 a,b cancomprise a side subpanel 1540 a,b respectively attached to the centerpanel 1610 and a flap subpanel 1640 a,b disposed opposite from thecenter panel 1610. Each side subpanel 1540 a,b can comprise a side tab1642 a,b, respectively. Each side tab 1642 a,b can be cut out from therespective flap subpanel 1640 a,b by a side tab cutout 1643 a,b,respectively. Each side tab 1642 a,b can be configured to extendoutwards from the flap subpanel 1640 a,b when the side tabs 1642 a,b arefolded relative to the flap subpanels 1640 a,b.

The first locking panel 1614 can comprise a side subpanel 1532 aattached to the center panel 1610 and a first locking subpanel 1510disposed opposite from the center panel 1610. The first locking subpanel1510 can comprise a pair of wings 1512 a,b, and each wing 1512 a,b candefine a locking slot 1514 a,b. The first locking subpanel 1510 can alsocomprise a channel tab 1530 a which can be cut out from the sidesubpanel 1532 a. The channel tab 1530 a can be configured to extendoutwards from the side subpanel 1532 a when the first locking subpanel1510 is folded relative to the side subpanel 1532 a.

The second locking panel 1616 can comprise a side subpanel 1532 battached to the center panel 1610 and a second locking subpanel 1520disposed opposite from the center panel 1610. The second lockingsubpanel 1520 can comprise a pair of locking tabs 1522 a,b which can behingedly attached to the second locking subpanel 1520. A pair of lockingnotches 1624 a,b can be defined between the second locking subpanel 1520and the locking tabs 1522 a,b. The second locking subpanel 1520 can alsocomprise a channel tab 1530 b which can be cut out from the sidesubpanel 1532 b. The channel tab 1530 b can be configured to extendoutwards from the side subpanel 1532 b when the second locking subpanel1520 is folded relative to the side subpanel 1532 b.

In an assembled configuration shown in FIG. 15 , the side subpanels 1532a,b,1540 a,b can define four sides of the inner box 1500. The centerpanel 1610 can define a bottom panel of the inner box 1500. The firstlocking subpanel 1510 and the second locking subpanel 1520 can overlapto define a top panel of the inner box 1500. The side flap panels 1618a,b can be folded inwards so that the flap subpanels 1640 a,b lie flatagainst the first locking subpanel 1510 and the second locking subpanel1520. The side tabs 1642 a,b can engage the locking slots 1514 a,b ofthe first locking subpanel 1510 to prevent the side flap panels 1618 a,bfrom unfolding. Additionally, locking tabs 1522 a,b can extend throughthe locking slots 1514 a,b and through openings defined by the side tapcutouts 1643 a,b to prevent the side flap panels 1618 a,b fromunfolding.

With the locking tabs 1522 a,b extending through the locking slots 1514a,b, the first locking subpanel 1510 can be secured to the secondlocking subpanel 1520. The locking notches 1624 a,b can engage thelocking slots 1514 a,b to prevent withdrawal of the locking tabs 1522a,b from the locking slots 1514 a,b. The second locking subpanel 1520can be positioned overlapping the first locking subpanel 1510, and thelocking tabs 1522 a,b can be inserted through the locking slots 1514 a,bto secure the first locking subpanel 1510 to the second locking subpanel1520.

The inner box 1500 can contain a temperature maintaining material 2110(shown in FIG. 21 ) within a cavity 2108 (shown in FIG. 21 ) of theinner box 1500, and the inner box 1500 can be configured to secure thetemperature maintaining material 2110 within the insulated box 110. Insome aspects, the inner box 1500 can contain a cooling material, such ascarbon dioxide dry ice for example and without limitation, configured tokeep contents of the insulated box 110 cold or frozen. In such aspects,as the dry ice sublimes into carbon dioxide gas, the cold carbon dioxidegas can pass downwards from the inner box 1500 through a plurality ofvents 1612 defined by the center panel 1610, which can be oriented asthe bottom panel. The inner box 1500 can prevent a user from makingdirect contact with the dry ice by which can cause burns to bare skin.In other aspects, the inner box 1500 can contain a different temperaturemaintaining material configured to cool the insulated box 110. Forexample, in some aspects, the temperature maintaining material 2110 canbe a mixture of materials configured to undergo a controlled endothermicreaction. For example and without limitation, the temperaturemaintaining material 2110 can comprise water, ammonium nitrate, calciumammonium nitrate, and/or urea in a container which can undergo anendothermic reaction as the water dissolves solid material in thecontainer, as commonly used in so-called “instant ice packs”. In suchaspects, the temperature maintaining material 2110 can absorb heatthrough the endothermic reaction.

In other aspects, the temperature maintaining material 2110 can be aheat emitting material configured to keep contents of the insulated box110 warm or hot. For example and without limitation, the inner box 1500can contain heat packs which emit residual heat from a heated materialdefining a high specific heat capacity. For example, a heated waterbottle or bag can emit residual heat over time. In other aspects, theinner box 1500 can contain a heat emitting material which can undergo acontrolled exothermic reaction to produce heat within the insulated box110. One example can include a pouch of supersaturated crystallizingsolution, such as sodium acetate for example and without limitation,which release heat as crystallization occurs as seen in some handwarmers. Another example can be a mixture which is commonly used in handwarmers which can comprise cellulose, iron, activated carbon,vermiculite, and/or salt which can release heat as oxygen oxidizes theiron as seen in other hand warmers. In such aspects, the temperaturemaintaining material 2110 can produce heat through the exothermicreaction.

FIG. 17 is a perspective view of another aspect of the insulated box 110in accordance with another aspect of the present disclosure. In thepresent aspect, the insulated box 110 can comprise the insulation wrap1730 configured to wrap or extend around the side panels 112 a,b,122 a,bof the box 101. In the present aspect, the insulation wrap 1730 may notcover the bottom end 104 of the box 101; however, in other aspects, theinsulation wrap 1730 can cover the bottom end 104 as well. Theinsulation wrap 1730 can comprise an insulation batt 2051 (shown in FIG.20 ) which can be thicker than the insulation batt 350 (shown in FIG. 3) of the insulation panels 130 a-d (shown in FIG. 3 ). In some aspects,the insulation batt 2051 can be 2″ in thickness or greater.

In the present aspect, the insulation wrap 1730 can be defined by oneinsulated panel 510 (shown in FIG. 5 ); however, in other aspects, theinsulation wrap 1730 can comprise a plurality of insulated panels 510attached together to encircle the box 101. In other aspects, theinsulation wrap 1730 can be formed differently from the insulated panels510. In the present aspect, opposite ends of the insulation wrap 1730can be attached together to form a seam 1732 which secures theinsulation wrap 1730 around the box 101. In the present aspect, theinsulation wrap 1730 can fit snuggly around the box 101, and frictionbetween the insulation wrap 1730 and the box 101 can prevent theinsulation wrap 1730 from slipping off of the box 101. In other aspects,the insulation wrap 1730 can be attached to the box 101 through amechanism such as staples, an adhesive, tape, hook-and-loop fasteners,or any other suitable attachment mechanism.

FIG. 18 is a perspective view of an outer sleeve 1800 of the modular boxassembly 100. The outer sleeve 1800 can be configured to fit over theinsulated box 110 of FIG. 1 , FIG. 17 , or any other aspect. With theouter sleeve 1800 fit over the insulated box 110, the insulation wrap1730 (shown in FIG. 17 ) or insulated panel 130 a-d (shown in FIG. 3)can be positioned between the box 101 and the outer sleeve 1800. Theouter sleeve 1800 can comprise four sides 1812 a,b,1822 a,b configuredto align with the side panels 112 a,b,122 a,b, respectively. In thepresent aspect, the side 1822 a can comprise a pair of side subpanels1824 a,b joined by a seam 1830. In other aspects, the seam 1830 can bepositioned at a corner of the outer sleeve 1800.

In the present aspect, the outer sleeve 1800 can comprise a rigidmaterial, such as corrugated cardboard for example and withoutlimitation. The outer sleeve 1800 can provide protection to theinsulated box 110, particularly the insulated panels 130 a-d orinsulation wrap 1730 of the insulated box 110. In the present aspect,the insulated panels 130 a-d and the insulation wrap 1730 can eachcomprise sheets of material, such as kraft paper for example and withoutlimitation, and the outer sleeve 1800 can prevent the sheets of materialfrom being damaged or torn during shipping or handling of the modularbox assembly 100. The outer sleeve 1800 can also provide substantiallyflat surfaces which can define graphics or indicia, such as logos,advertisements, decorations, indications of the contents, handlingwarnings such as “Fragile” or “This Side Up”, or any other indicia forexample and without limitation. The outer sleeve 1800 can also provideadditional insulation value to the insulated box 110.

FIG. 19 is a perspective view of a support bracket 1910 of the modularbox assembly 100 mounted within the box cavity 206 of the box 101. Thesupport bracket 1910 can be configured to support items within the boxcavity 206 such as the insulated cavity panel 430, the inner box 1500,the divider panel 2230 (shown in FIG. 22 ), or any other item,partition, insulation, or barrier. As demonstrated by the shoulder 222a, each shoulder 222 a,b (shoulder 222 b shown in FIG. 20 ) can define ashoulder channel 1922 a,b (shoulder channel 1922 b shown in FIG. 20 ).The shoulder channel 1922 a can be representative of both shoulderchannels 1922 a,b. The shoulder channel 1922 a can be defined by theside panel 122 a and the two sub-shoulders 322 a,b of the shoulder 222a.

The bracket 1910 can comprise a channel tab 1912 and a support shelf1914, and the channel tab 1912 can be folded to be substantiallyperpendicular to the support shelf 1914. In the aspect shown, thebracket 1910 can further comprise a brace 1920 which can extend betweenthe support shelf 1914 and the channel tab 1912. The brace 1920 can befolded inward between the channel tab 1912 and the support shelf 1914 toprevent the support shelf 1914 from folding in half towards the channeltab 1912 when a downward load is applied to the support shelf 1914.

The channel tab 1912 can be configured to frictionally engage thesub-shoulders 322 a,b to secure the bracket 1910 within the shoulderchannel 1922 a. The channel tab 1912 can define a top end 1916 and abottom end 1918. The support shelf 1914 can be attached to the channeltab 1912 at the top end 1916 in the present aspect. In some aspects, thechannel tab 1912 can taper from the top end 1916 to the bottom end 1918.The taper can ensure that the bottom end 1918 can easily be insertedinto the shoulder channel 1922 a while still providing sufficientfriction between the sub-shoulders 322 a,b and the channel tab 1912 tosecure the channel tab 1912 within the shoulder channel 1922 a.

In the present aspect, the first wings 312 a,c can be substantiallyflush with the second wings 324 a,b of the sub-shoulders 322 a,b. Inother aspects, the first wings 312 a,c can extend further into thesupport channel 1922 a than the second wings 324 a,b to provide a groove(not shown) between the first wing 312 a, the second wing 324 b, and theside panel 122 a and another groove between the first wing 312 c, thesecond wing 324 b, and the side panel 122 a. In such aspects, thegrooves can capture the channel tab 1912 such that a portion of thechannel tab 1912 is positioned between the first wing 312 a and the sidepanel 122 a and another portion of the channel tab 1912 is positionedbetween the first wing 312 c and the side panel 122 a. By capturing thechannel tab 1912, the grooves can prevent the bracket 1910 from beingpulled outwards from the shoulder channel 1922 a in a direction awayfrom the side panel 122 a.

FIG. 20 is a downward cross-section of another aspect of the modular boxassembly 100. In the present aspect, the modular box assembly 100 cancomprise the insulated box 110 of FIG. 17 which can be nested within theouter sleeve 1800 of FIG. 18 . The inner box 1500 of FIG. 15 can bedisposed within the box cavity 206 of the box 101 of the insulated box110. The aspect of FIG. 20 is but one possible combination of elementswhich demonstrates the modularity and flexibility of the modular boxassembly 100.

The insulation wrap 1730 of the insulated box 110 can be positionedbetween the box 101 and the outer sleeve 1800 in the present aspect. Theinsulation wrap 1730 can comprise the insulation batt 2051 which can beencapsulated between a first sheet 2052 and a second sheet 2054 of theinsulation wrap 1730 by a border 2058. The border 2058 can attach thefirst sheet 2052 to the second sheet 2054, and the border 2058 can fullyenclose the insulation batt 2051. A first border portion 2032 a of theborder 2058 can be attached to a second border portion 2032 b of theborder 2058 to form the seam 1732 which can secure the insulation wrap1730 around the box 101. The first border portion 2032 a and the secondborder portion 2032 b can be defined at opposite ends of the insulationwrap 1730.

In the present aspect, the first sheet 2052 can be in facing contactwith the outer sleeve 1800, and the second sheet 2054 can be in facingcontact with the box 101. In some aspects, the second sheet 2054 of thesecond border portion 2032 b can be attached to the box 101, such aswith an adhesive, and then the first border portion 2032 a can beattached to the second border portion 2032 b, such as with an adhesive,to secure the insulation wrap 1730 around the box 101.

The inner box 1500 can be sized to fit closely within the box cavity206. The wings 1512 a,b can contact the side panels 112 a,b. The channeltabs 1530 a,b can extend outwards from the inner box 1500 and into theshoulder channels 1922 a,b. The channel tabs 1530 a,b can be sized andconfigured to frictionally engage the shoulder channels 1922 a,b tosecure and suspend the inner box 1500 within the box cavity 206, asfurther shown in FIG. 21 .

FIG. 21 is a side cross-section of the modular box assembly 100 of FIG.20 , further comprising the handle top 1190 of FIG. 11 . As describedabove, the inner box 1500 can be suspended within the box cavity 206,and the inner box 1500 can divide the box cavity 206 into a firstsub-compartment 2106 a and a second sub-compartment 2106 b. In aspectsin which the temperature maintaining material 2110 can be a coolingmaterial, such as dry ice, the first sub-compartment 2106 a can containfrozen goods, and the second sub-compartment 2106 b can contain chilledgoods. Dense, cold air from the temperature maintaining material 2110can descend downwards from the temperature maintaining material 2110through the vent holes 1612 (shown in FIG. 16 ) into the firstsub-compartment 2106 a to maintain a colder temperature in the firstsub-compartment 2106 a compared to the second sub-compartment 2106 b.

In aspects in which the temperature maintaining material 2110 can be aheat emitting material, the second sub-compartment 2106 b can maintain atemperature higher than the first sub-compartment 2106 a due to risinghot air from the temperature maintaining material 2110. In such aspects,the inner box 1500 can be turned upside down with the center panel 1610facing upwards to promote convection through the vent holes 1612 withinthe second sub-compartment 2106 b. In some aspects, the insulated cavitypanel 430 (shown in FIG. 4 ) can be placed beneath the handle top 1190to resist heat transfer through the handle top 1190.

As shown, a portion of the first tape strip 1393 a can attach to aportion of the second tape strip 2192 a between the side panel 1196 aand the top panel 1192 to form the living hinge 1310 a of the handle top1190. A portion of the first tape strip 1393 b can attach to a portionof the second tape strip 2192 b between the side panel 1196 b and thetop panel 1192 to form the living hinge 1310 b.

In the present aspect, the modular box assembly 100 can further comprisethe bottom insulated panel 2130. The bottom insulated panel 2130 cancomprise a sheet 2152, a board 2154, and an insulation batt 2150. In thepresent aspect, the insulation batt 2150 can be encapsulated andlaminated to the board 2154 by the sheet 2152. The sheet 2152 cancomprise a thin, flexible material such as a film, a paper, a fabric, amesh, or any other suitable material. The board 2154 can comprise arigid material, such as cardboard, a plastic, a metal, a rigid foam, orany other suitable material. The bottom insulated panel 2130 can restatop the bottom panel 306 of the box 101, and the bottom insulated panel2130 can provide insulation for the bottom end 104 of the box 101.

The rigidity of the board 2154 can be desirable to prevent collapse ofthe box 101 or insulated box 110 during shipping or handling of the box101 or insulated box 110. Collapse of one aspect of the insulated box110 is demonstrated in FIG. 8 . Inadvertent or accidental collapse ofthe box 101 or insulated box 110 during shipping or handling can crushor damage the contents of the box 101 or insulated box 110. By placingthe board 2154 against the bottom panel 306, the rigidity of the board2154 can prevent folding of the bottom panel 306 along the center foldline 382 (shown in FIG. 7 ), the corner fold lines 384 a-d (shown inFIG. 7 ), and the V-shaped fold lines 386 a-f (shown in FIG. 7 ),thereby preventing collapse of the insulated box 110 or box 101. In someapplications, the board 2154, without the insulation batt 2150 and sheet2152, can be placed atop the bottom panel 306 to prevent collapse asshown in FIG. 22 .

FIG. 22 is a side cross-section of another aspect of the modular boxassembly 100. In the present aspect, the modular box assembly 100 cancomprise the handle top 1190 and the insulated box 110 of FIG. 17 whichcan be nested within the outer sleeve 1800 of FIG. 18 . The modular boxassembly 100 can further comprise the support brackets 1910 of FIG. 19which can engage the shoulder channels 1922 a,b of the box 101. Themodular box assembly 100 can further comprise the divider panel 2230which can be suspended within the box cavity 206 by the support brackets1910.

The divider panel 2230 can comprise a first sheet 2252, a second sheet2254, a pair of insulation batts 2250 a,b, and a board 2256. In thepresent aspect, the board 2256 can be a rigid board; however in otheraspects, the board 2256 can be a flexible or resilient board. The board2256 can be positioned between the insulation batts 2250 a,b, and theboard 2256 and the insulation batts 2250 a,b can be encapsulated betweenthe first sheet 2252 and the second sheet 2254. The first sheet 2252 andthe second sheet 2254 can be joined by a border 2258 which can extendaround the divider panel 2230 to fully enclose the board 2256 andinsulation batts 2250 a,b. The divider panel 2230 can divide the boxcavity 206 into a first sub-compartment 2206 a and a secondsub-compartment 2206 b, and the divider panel 2230 can insulate thefirst sub-compartment 2206 a from the second sub-compartment 2206 b. Theborder 2258 can also form a seal with the box 101 to isolate the firstsub-compartment 2206 a from the second sub-compartment 2206 b. In otheraspects, the divider panel 2230 may not be suspended by the supportbrackets 1910 but can instead rest upon contents of the firstsub-compartment 2206 a, and the compressible nature of the lowerinsulation batt 2250 b can allow the divider panel 2230 to conform tothe contents of the first sub-compartment 2206 a. The divider panel 2230can provide increased rigidity compared to the insulated cavity panel430 (shown in FIG. 4 ) which can be desirable for applications in whichthe divider panel 2230 supports a load.

In the present aspect, the modular box assembly 100 can further comprisea bag 2200 disposed within the second sub-compartment 2206 b. In otheraspects, the bag 2200 can be disposed within the first sub-compartment2206 a, or the bag 2200 can fill the box cavity 206 in undividedapplications. In the present aspect, the bag 2200 can be sealed by aroll top seal 2204 to enclose a bag cavity 2202. In the present aspect,the bag 2200 can comprise a thermally reflective material or radiantbarrier, such as a metal foil or a metalized plastic such as mylar, forexample and without limitation. The bag 2200 can be configured tomaintain higher or lower temperatures within the bag cavity 2202relative to a temperature within the box cavity 206.

The modular box assembly 100 can further comprise temperaturemaintaining packs 2208 which can each comprise a temperature maintainingmaterial 2210 enclosed in a container 2212. The temperature maintainingmaterial 2210 can be similar to the temperature maintaining material2110 (shown in FIG. 21 ), or the temperature maintaining material 2210can comprise a different material than the temperature maintainingmaterial 2110. The container 2212 can be a soft container such as aplastic bag, foil pack, fabric sack, or any other suitable softcontainer, or the container 2212 can be a hard container such as aplastic bottle, metal case, or any other suitable hard container.

The temperature maintaining packs 2208 can be configured to maintainhigher or lower temperatures within the box cavity relative to anambient temperature outside of the box cavity 206. For example, incooling applications, the temperature maintaining material 2210 canabsorb heat through a phase change such as melting ice or subliming dryice, an endothermic reaction such as dissolving solid solute within asolvent, or warming of a chilled material, heat sink, or cold platedefining a temperature below the ambient temperature. In heatingapplications, the temperature maintaining material 2210 can release heatthrough a phase change such as condensation or solidification, anexothermic reaction such as oxidation or solid crystal nucleation in asupersaturated solution, or cooling of a heated material or heat sourcedefining a temperature above the ambient temperature.

The temperature maintaining packs 2208 can be sized and shaped to coverthe board 2154 or the bottom panel 306 of the box 101, similar tobricks, to form a first layer. In other aspects, an insulated panel,such as the insulated cavity panel 430 or the bottom insulated panel2130 can be placed between the temperature maintaining packs 2208 andthe bottom panel 306 to reduce heat transfer through the bottom end 104of the box 101. Contents of the box 101 can be placed atop thetemperature maintaining packs 2208, or in some aspects, another layer oftemperature maintaining packs 2208 can be placed atop the first layer oftemperature maintaining packs 2208 to provide increased heating orcooling time for contents of the box cavity 206. The temperaturemaintaining packs 2208 can be placed in both or either of the firstsub-compartment 2206 a and the second sub-compartment 2206 b or inundivided applications, the temperature maintaining packs 2208 can beplaced anywhere within the box cavity 206. In some aspects, thetemperature maintaining packs 2208 can be used in the same box cavity206 with the inner box 1500 and the temperature maintaining material2110, for example and without limitation, to provide increased heatingor cooling time for contents of the box cavity 260.

FIG. 23 is an exploded perspective view of another aspect of theinsulated box 110 in accordance with another aspect of the presentdisclosure. The insulated box 110 of the present aspect can be aninternally insulated box. The insulated box 110 can comprise an A-Bliner 2310 which can comprise a first liner 2312 a and a second liner2312 b. The first liner 2312 a and the second liner 2312 b can each bedefined by insulated panels 510 which can each be folded into a C-shape.

The first liner 2312 a can define a center panel 2314 a disposed betweena first side panel 2316 a and a second side panel 2316 b. A border 158of the first liner 2312 a can comprise a first end border portion 2320 adefined by the first side panel 2316 a and a second end border portion2320 b defined by the second side panel 2316 b and disposed oppositefrom the first end portion 2320 a. A fold 2318 a can be defined betweenthe first side panel 2316 a and the center panel 2314 a, and a fold 2318b can be defined between the second side panel 2316 b and the centerpanel 2314 a. A pair of side border portions 2322 a,b of the border 158can be defined by the side panels 2316 a,b and the center panel 2314 a,and the side border portions 2322 a,b can extend between the respectiveend border portions 2320 a,b.

The second liner 2312 b can define a center panel 2314 b disposedbetween a first side panel 2316 c and a second side panel 2316 d. Aborder 158 of the second liner 2312 b can comprise a first end borderportion 2320 c defined by the first side panel 2316 c and a second endborder portion 2320 d defined by the second side panel 2316 d anddisposed opposite from the first end border portion 2320 c. A fold 2318c can be defined between the first side panel 2316 c and the centerpanel 2314 b, and a fold 2318 d can be defined between the second sidepanel 2316 d and the center panel 2314 b. A pair of side border portions2322 c,d of the border 158 can be defined by the side panels 2316 c,dand the center panel 2314 b, and the side border portions 2322 c,d canextend between the respective end border portions 2320 c,d.

The liners 2312 a,b can fit together to define a substantially cubic orrectangular prism shape with an inner insulated cavity (not shown)defined by the A-B liner 2310. The end border portions 2320 a,b of theborder 158 of the first liner 2312 a can contact the center panel 2314 bof the second liner 2312 b, and the end border portions 2320 c,d of theborder 158 of the second liner 2312 b can contact the center panel 2314a of the first liner 2312 a. The side border portions 2322 c,d of theborder 158 of the second liner 2312 b can each extend around the sidesof a different one of the side panels 2316 a,b. The side border portions2322 a,b of the border 158 of the first liner 2312 a can each extendaround the sides of a different one of the side panels 2316 c,d.

In the present aspect, the A-B liner 2310 can be oriented so that thecenter panel 2314 a of the first liner 2312 a covers the box opening 106of the box 101, the center panel 2314 b of the second liner 2312 bcovers the bottom panel 306, and the side panels 2316 a,b,c,d cover theside panels 112 a,b,122 a,b of the box 101. In the present aspect, theside panels 2316 a,b can cover the side panels 122 a,b, and the sidepanels 2316 c,d can cover the side panels 112 a,b. In other aspects, theside panels 2316 a,b can cover the side panels 112 a,b, and the sidepanels 2316 c,d can cover the side panels 122 a,b.

In still other aspects, the A-B liner 2310 can be orientated such thatthe first side panel 2316 a of the first liner 2312 a covers the boxopening 106, and the second side panel 2316 b of the first liner 2312 acovers the bottom panel 306 of the box 101. The side panels 112 a,b,122a,b of the box 101 can be covered by the second liner 2312 b and thecenter panel 2314 a of the first liner 2312 a. Such a configuration canbe desirable because the first side panel 2316 a can act as a lid whichcan be folded about the fold 2318 a to open and close the innerinsulated cavity of the A-B Liner 2310 without requiring removal ofeither of the liners 2312 a,b from the box 101.

In the present aspect, the sheets 352,354,2052,2054,2152,2252,2254 cancomprise paper, such as kraft paper; however, in other embodiments, thesheets can comprise posterboard, cardboard, plastic sheeting, cellulosefilm, cloth, or any other suitable material. In some aspects, the sheetscan comprise a water-proof or water-resistant material, such aswater-proof paper. In some aspects, a one of the sheets352,354,2052,2054,2152,2252,2254 of the modular box assembly 100 cancomprised a material different from another of the sheets352,354,2052,2054,2152,2252,2254. In the present aspect, the box 101 cancomprise a paper fiber-based material such as corrugated cardboard orposter board; however, the box 101 can comprise any suitable rigid boardmaterial such as wood, plastic, metal, or any other material.

The insulation batts 350,2051,2150,2250 a,b can comprise paper or otherpaper fiber materials; however, in other aspects, the insulation battscan comprise cotton, foam, rubber, plastics, fiberglass, mineral wool,or any other flexible insulation material. In the present application,the insulation batts can be repulpable. In the present aspect, themodular box assembly 100 can be 100% recyclable. In the present aspect,the modular box assembly 100 can be single-stream recyclable wherein allmaterials comprised by the modular box assembly 100 can be recycled by asingle processing train without requiring separation of any materials orcomponents of the modular box assembly 100. In the present aspect, themodular box assembly 100 can be compostable. In the present aspect, themodular box assembly 100 can be repulpable. In the present aspect, themodular box assembly 100 and each of the insulated box 110, the toppanel 190, the insulated panels 130 a-d,430,140,510, the insulation wrap1730, the bottom insulated panel 2130, the divider panel 2230, and theliners 2312 a,b can be repulpable in accordance with the requirements ofthe Aug. 16, 2013, revision of the “Voluntary Standard For Repulping andRecycling Corrugated Fiberboard Treated to Improve Its Performance inthe Presence of Water and Water Vapor” provided by the Fibre BoxAssociation of Elk Grove Village, Ill. which is hereby incorporated inits entirety. In the present aspect, the modular box assembly 100 andeach of the insulated box 110, the top panel 190, the insulated panels130 a-d, 430,140,510, the insulation wrap 1730, the bottom insulatedpanel 2130, the divider panel 2230, and the liners 2312 a,b can berecyclable in accordance with the requirements of the Aug. 16, 2013,revision of the “Voluntary Standard For Repulping and RecyclingCorrugated Fiberboard Treated to Improve Its Performance in the Presenceof Water and Water Vapor” provided by the Fibre Box Association of ElkGrove Village, Ill.

Recyclable and repulpable insulation materials are further described inU.S. Provisional Patent Application No. 62/375,555, filed Aug. 16, 2016,U.S. Provisional Patent Application No. 62/419,894, filed Nov. 9, 2016,and U.S. Provisional Patent Application No. 62/437,365, filed Dec. 21,2016, which are each incorporated by reference in their entirety herein.

Further regarding the manufacture and composition of the insulationbatts 350,2051,2150,2250 a,b, one or more of the three above-identifiedapplications, such as U.S. Provisional Patent Application No.62/375,555, disclose that insulative pads/batts can be manufacturedfiber compositions formed by passing recycled cardboard through a millsuch as a hammer mill. Optionally, the batts may also be formed from arandomly-distributed mixture of reinforcement fibers comprising naturalfibers, such as cotton, and binder fibers having a length between 1/16inch to 1.5 inches and a denier of between 5 and 12. The binder fibers,along with the reinforcement fibers, can be laid randomly yetconsistently in x-y-z axes. The reinforcement fibers are generally boundtogether by heating the binder fibers above their glass transitiontemperature. As disclosed in U.S. Provisional Patent Applications Nos.62/419,894 and 62/437,365, what have heretofore been described asreinforcement fibers may also comprise a mixture of recycled cardboardand paper fibers, ranging from and including a 50/50 cardboard/paper mixto and including a 75/25 cardboard/paper mix. The batt material usingsuch reinforcement fibers can comprise 75% cardboard/paper mixture and25% binder fiber, such batt material having a density of 1600 grams persquare meter (“GSM”). Additional materials constructed are 80/20 at 1500GSM; 80/20 at 1400 GSM; 85/15 at 1600 GSM; 85/15 at 1500 GSM; 85/15 at1400 GSM; and 90/10 at 1500 GSM, with the first number being thepaper/cardboard fiber mixture percentage and second number being abinder fiber percentage (for example, 80/20 is 80% paper/cardboard fibermixture and 20% binder fiber).

As disclosed in at least U.S. Provisional Patent Application No.62/375,555, typically, less than about 20% by weight binder fiber isused to form the insulation batts 350,2051,2150,2250 a,b. The binderfibers are preferably thermoplastic fibers selected from the groupcontaining polyethylene, polyester or polypropylene, or mixturesthereof. As further disclosed in U.S. Provisional Patent ApplicationsNos. 62/419,894 and 62/437,365, the binder fibers may also comprisewater soluble and recyclable polyvinyl alcohol (“PVOH”), as well asmixtures of PVOH with any of the aforementioned binder fiber materials.The fiber can be for example a KURALON™ brand short cut fibers. As abinder fiber, the recyclable PVOH fiber used in the insulation can be a0.4 to 1.0 denier fiber having a length of 3.0-4.0 mm. As still furtherdisclosed in U.S. Provisional Patent Application No. 62/437,365, thebinder fiber may be a bi-component fiber comprising polyethylene (“PE”)and polypropylene (“PP”). The PE/PP ratio of this bi-component fiber canrange between 50/50 and about 65/35, or it may have the 65/35 PE/PPratio. Such bi-component fibers may be available under the name ESFIBERVISIONS®, including under product codes EAC, EPS, ESC, ESE, EDC,Herculon T426, and Herculon T457. The binder fibers may also beconstructed of recyclable or biodegradable material. The thermoplasticbinder fibers may have a weight of less than 0.2 pounds per square footand, more particularly, preferably about 0.1875 pounds per square foot.The remaining reinforcement fiber may be greater than 0.8 pounds persquare foot, and preferably 1.0625 pounds per square foot.

Also as disclosed in at least U.S. Provisional Patent Application No.62/375,555, the material comprising batts 350,2051,2150,2250 a,b isheated in an oven to a temperature greater than about 350° F. and, morepreferably, to a temperature of about 362° F. Such heating causes thebinder fibers to melt and couple to the non-binder fibers, thus causingfibers to adhere to each other and solidify during cooling. Uponcooling, the binder fibers solidify and function to couple thenon-binder reinforcement fibers together as well as function asreinforcement themselves.

The modular box assembly 100 can be used in applications in which a useror mail carrier transports perishable or temperature-sensitive goods,such as frozen, chilled, or hot goods. For example and withoutlimitation, the modular box assembly 100 can be used to transportgroceries, medications, electronics, or any other goods. The modular boxassembly 100 can improve upon a common cardboard box by providinginsulation to prevent spoilage of the contents. The modular box assembly100 can also be used to deliver hot goods, such as warm foods.

In order to ship temperature-sensitive goods, common cardboard boxes areoften packed with insulating materials made of plastics or foams whichare not accepted by many recycling facilities or curb-side recyclingprograms in which a waste management service collects recyclables at auser's home. Consequently, shipping temperature-sensitive goods oftenproduces non-recyclable waste which is deposited in landfills. Theinsulation materials often decompose very slowly, sometimes over thecourse of several centuries. In some instances, non-recyclable andnon-biodegradable insulating materials can enter the oceans where theinsulation materials can remain for years and harm marine life. In someaspects, the modular box assembly 100 can reduce waste and pollution bycomprising materials which are recyclable or biodegradable. In aspectsin which the modular box assembly 100 is curb-side or single-streamrecyclable, the user may be more likely to recycle the modular boxassembly 100 due to the ease of curb-side collection.

One should note that conditional language, such as, among others, “can,”“could,” “might,” or “may,” unless specifically stated otherwise, orotherwise understood within the context as used, is generally intendedto convey that certain embodiments include, while other embodiments donot include, certain features, elements and/or steps. Thus, suchconditional language is not generally intended to imply that features,elements and/or steps are in any way required for one or more particularembodiments or that one or more particular embodiments necessarilyinclude logic for deciding, with or without user input or prompting,whether these features, elements and/or steps are included or are to beperformed in any particular embodiment.

It should be emphasized that the above-described embodiments are merelypossible examples of implementations, merely set forth for a clearunderstanding of the principles of the present disclosure. Any processdescriptions or blocks in flow diagrams should be understood asrepresenting modules, segments, or portions of code which include one ormore executable instructions for implementing specific logical functionsor steps in the process, and alternate implementations are included inwhich functions may not be included or executed at all, may be executedout of order from that shown or discussed, including substantiallyconcurrently or in reverse order, depending on the functionalityinvolved, as would be understood by those reasonably skilled in the artof the present disclosure. Many variations and modifications may be madeto the above-described embodiment(s) without departing substantiallyfrom the spirit and principles of the present disclosure. Further, thescope of the present disclosure is intended to cover any and allcombinations and sub-combinations of all elements, features, and aspectsdiscussed above. All such modifications and variations are intended tobe included herein within the scope of the present disclosure, and allpossible claims to individual aspects or combinations of elements orsteps are intended to be supported by the present disclosure.

That which is claimed is:
 1. A modular box assembly comprising: a box,the box comprising a bottom box panel and four side box panels, the fourside box panels and the bottom box panel defining a box cavity; a firstthermal liner positioned within the box cavity, the first thermal linercomprising a first sheet, a second sheet, and a first insulation battdisposed between the first sheet of the first thermal liner and thesecond sheet of the first thermal liner, the first insulation batt fullyencapsulated in a single cavity defined between the first sheet and thesecond sheet, the first thermal liner defining three first liner panelsformed as a single piece of insulation material, the three first linerpanels each positioned within the single cavity, wherein at least oneside box panel is covered by a first liner panel; and a second thermalliner positioned within the box cavity, the second thermal linercomprising a first sheet, a second sheet, and a second insulation battdisposed between the first sheet of the second thermal liner and thesecond sheet of the second thermal liner, the second thermal linerdefining three second liner panels, wherein at least one other of theside box panels is covered by a second liner panel; wherein the bottombox panel is covered by one of a first liner panel not covering any sidebox panel and a second liner panel not covering any side box panel; andwherein each of the first insulation batt and the second insulation battis formed from a mixture of thermoplastic binder fibers andreinforcement fibers.
 2. The modular box assembly of claim 1, whereinthe thermoplastic binder fibers are biodegradable.
 3. The modular boxassembly of claim 1, wherein the thermoplastic binder fibers arecomposed of at least one of polyethylene, polyester, and polypropylene.4. The modular box assembly of claim 1, wherein the first thermal linerand the second thermal liner are each folded into a C-shape.
 5. Themodular box assembly of claim 1, wherein the thermoplastic binder fiberseach have a length measuring less than 1.5 inches.
 6. The modular boxassembly of claim 5, wherein the thermoplastic binder fibers each have alength measuring between 1/16 inches and 1.5 inches.
 7. The modular boxassembly of claim 5, wherein the thermoplastic binder fibers each have adenier of between 5 and
 12. 8. The modular box assembly of claim 1,wherein each of the first insulation batt and the second insulation battcomprises less than about 20% by weight of thermoplastic binder fibers.9. The modular box assembly of claim 8, wherein the thermoplastic binderfibers have a weight less than 0.2 pounds per square foot.
 10. Themodular box assembly of claim 9, wherein the thermoplastic binder fibershave a weight of about 0.1875 pounds per square foot.
 11. The modularbox assembly of claim 1, wherein the reinforcement fibers exceed 0.8pounds per square foot.
 12. The modular box assembly of claim 11,wherein the reinforcement fibers weigh 1.0625 pounds per square foot.13. The modular box assembly of claim 1, wherein the first sheet of thefirst thermal liner and the first sheet of the second thermal liner eachcomprise paper.
 14. The modular box assembly of claim 13, wherein thesecond sheet of the first thermal liner and the second sheet of thesecond thermal liner each comprise paper.